van's aircraft, inc. section 40is/u: lighting
TRANSCRIPT
PARTICIPANTS:
DATE OF COMPLETION:
PAGE:REVISION:DATE:
VAN'S AIRCRAFT, INC.
40iS/U-01RV-12iS103/11/19
SECTION 40iS/U:LIGHTING
NOTE: Special tools required to complete thissection include an abrasive cutting disk and aremovable Vis-A-Vis marker.
W-1223B-LLANDINGLIGHT RIB
LN-200-1WING TIP NAV/POSITION/
STROBE LIGHT
RIGHT WING
W-1222-REXTENSION
W-00036LENS
LL-200LANDING LIGHT
W-1223ELENS BACKING STRIP,
2 PLACES
40iS/U-03RV-12iS103/11/19 PAGE:REVISION:DATE:
VAN'S AIRCRAFT, INC.Step 8: Machine countersink the rivet holes in both W-1223E LensBacking Strips at all nutplate attach locations.
Rivet nutplates to both of the W-1223E as shown in Figure 2.
FIGURE 2: ADDING NUTPLATESTO THE LENS BACKING STRIPS
Step 9: Temporarily position the W-1223E on the W-00036as shown in Figure 3.
Use the edge of the W-1223E to mark the W-00036 fortrimming.
Step 10: Trim back the corners of the W-00036 to matchthe edges of the W-1223E as shown in Figure 3.
Step 11: Radius the edges of the W-00036.
Smooth all trimmed edges with 220 grit sandpaper.
Deburr the interior sides of the screw holes.
4XK1000-062X AN426AD3-3.5
FIGURE 1: FITTINGTHE LENS
2X 1/4 [6.4 mm]TWO
CENTERHOLES
Step 1: Wrap masking tapearound each end of theW-00036 then insert theW-000136 into the opening inthe W-1203-R-1. See Figure 1.
Step 2: Use the tape to hold theW-00036 tight against theW-1203-R-1.
Match-Drill #30 using a plexi bitand cleco the eight holes in theW-1203-R-1 surrounding thelanding light cutout in theW-00036. See Figure 1.
Step 3: Mark the inbd and outbdedges of the landing light cutoutin the W-1203-R-1 onto theW-00036 with a wet-eraseVis-A-Vis marker or equivalent.See Figure 1.
Step 4: Remove the W-00036and the tape.
Final-Drill #27 using a plexi bitthe holes in the W-00036.
Step 5: Trim the W-00036 usingthe dimensions in Figure 1 andthe reference marks made inStep 3.
Start by trimming within 1/32inch of the final shape with anabrasive cutting diskthen finish by sanding.
Step 6: Final-Drill #27, debur,then dimple the eight holes inthe W-1203-R-1 surrounding thelanding light cutout for the headof a #6 screw.
Step 7: Machine countersinkthe screw holes in theW-00036 for the correspondingdimples in the W-1203-R-1.
FIGURE 3: ROUNDING THECORNERS OF THE LENS
W-1223E
W-1203-R-1
W-00036
2X TAPE 2X MARKEND OFCUTOUT
W-00036
6-32 SCREW,TYP.
2X W-1223E
4X REMOVEDHATCHED AREA
40iS/U-05RV-12iS108/27/19 PAGE:REVISION:DATE:
VAN'S AIRCRAFT, INC.
1
3
4
2
1
3
4
2
YEL
BLK
BLU
RED
GRN
BLK
L216
ES-00077 WH-00033
RE
DL
214
YE
LL
213
GR
NL
6312
WH
T
WH
T/O
RN
WH
T/B
LU
L6310
WH
T
GRNL6310
BLKL215
BLKL211
WHT
WHT/ORN
WHT/BLU
GRNL6312
YELL213
REDL214
NAV/
POSITION/
STROBE
BLK
RED
YEL
GRN
LANDING LIGHT
RIGHT WINGROOT CONNECTOR
1 63 4 52 7 8
BLK
L216
ES-00078 WH-00032
WH
TW
218
RE
DL
214
YE
LL
213
BLU
L7514
WH
T
WH
T/O
RN
WH
T/B
LU
L6310
WH
T
GRNL6310
BLKL215
BLKL211
WHT
WHT/ORN
WHT/BLU
NAV/
POSITION/
STROBE
BLK
RED
YEL
GRN
YEL
BLK
BLU
RED
GRN
LANDING LIGHT
W217
BLK
STALL WARN
SWITCH
LEFT WINGROOT CONNECTOR
BLUL7514
YELL213
REDL214
FIGURE 1: WING WIRING SCHEMATICS
1
3
4
2
1
3
4
2
1
3
4
2
1
3
4
2
1
3
4
2
1
3
4
2
1 63 4 52 7 8
W218
WH
T
L6309 BLK
L6309 BLK
MALE MOLEX
CONNECTOR HOUSING
FEMALE MOLEX
CONNECTOR HOUSING
MALE MOLEX
CONNECTOR HOUSING
FEMALE MOLEX
CONNECTOR HOUSING
NOTE: See section 5.21 for more information on aircraft electrical systems.
MALE MOLEX
CONNECTOR HOUSING
FEMALE MOLEX
CONNECTOR HOUSING
MALE MOLEX
CONNECTOR HOUSING
FEMALE MOLEX
CONNECTOR HOUSING
HEATSHRINK
OVER CONTACT
HEATSHRINK
OVER CONTACT
40iS/U-07RV-12iS103/11/19 PAGE:REVISION:DATE:
VAN'S AIRCRAFT, INC.
FIGURE 1: INSTALLING THELANDING LIGHT
(VIEW FROM INSIDE THE RIGHT WING)
Step 1: Strip the ends of the wires coming from the back of the LL-200 Landing Light.
Crimp on male Molex pins to the end of each wire.
Step 2: Shrink a piece of heatshrink over the Molex pin on the blue wire of the first LL-200, designating this LL-200 the right landinglight.
Step 3: If installing dual landing lights, shrink a piece of heatshrink over the Molex pin on the green wire of the second LL-200,designating this LL-200 the left landing light.
Step 4: Snap the Molex pins on the LL-200 wires into the female Molex connector housing in accordance with the wiring schematic onPage 40iS/U-05.
Step 5: Connect the male and female Molex connector housings for the LL-200. Secure the wires with tie-wraps as necessary toprevent chafing. See Figure 1.
Step 6: Install the LL-200 onto the W-1223B-L & -R using the hardware called out in Figure 1. First align the attach holes in the LL-200with the aft end of the slot in the W-1223B-L & -R, start the bolt with washers by hand then slide the LL-200 forward to the front of theslots.
Aim the light slightly downward so that the front face of the LL-200 is parallel to the front edge of the W-1223B-L & -R.
Finish tightening the bolts using a box end wrench while continuing to hold the front face of the LL-200 parallel to the front edge of theW-1223B-L & -R. See Figure 1.
Step 7: Use two pieces of double backed tape to hold the W-1223E to theinside face of the W-00036. See Figure 2.
Step 8: Slip the W-00036 through the landing light cutout in the W-1203-R-1and screw it in place as shown in Figure 2.
Use tape to make temporary pull tabs to hold the W-00036 against theW-1203-R-1 and help start the screws.
FIGURE 2: INSTALLING THE LENS
W-1203-R-1
FRONT FACEOF LL-200
PARALLEL TO FRONT
EDGE OFW-1223B-L
2X AN3-3A
2X AEROLEDSLOCKWASHER
W-1223B-L
2X AEROLEDSFLAT WASHER
SLOTLL-200
W-1223B-R
TIE-WRAPSAS REQ'D
MOLEXCONNECTORHOUSING
W-00036
2X W-1223E
8X AN507C632R6(OPTIONAL AN507-632R6 IF YOU
WISH TO PAINT THE HEADSOF THE SCREWS)
40iS/U-11RV-12iS202/14/20 PAGE:REVISION:DATE:
VAN'S AIRCRAFT, INC.NOTE: If the cockpit light wires were bundled and secured under the baggage floor while completing Section 42MiS/U (in
anticipation of not installing the lighting kit), return to Section 42MiS/U and route the cockpit light wires throughout the roll
bar as instructed before completing the steps on this page.
Step 1: Remove the two lower right rivets that hold the F-1231A-FR Roll Bar Frame and F-1231E Roll Bar Splice Plate together using a
#30 bit. See Figure 1.
Step 2: Cleco the F-12124 to the two holes created in Step 1.
Step 3: Match-Drill #30 the right two holes in the F-12124 into the web of the F-1231A-FR.
Step 4: Machine countersink the three holes in the F-12124 Light Bracket for attaching the Cockpit Light and Dimmer Assembly.
Final-Drill #30 the 3 holes in the LC ECL-02 Red Eyeball Cockpit Light.
Step 5: Prep and paint the F-12124.
Step 6: Rivet the F-12124 to the web of the F-1231A-FR as shown in Figure 1.
Step 7: Crimp an ES-00141 butt splice to the black wire from the LC ECL-02 Red Eyeball Cockpit Light.
Crimp an ES-00141 butt splice to the red wire from the ES-00338 Potentiometer, as shown in Figure 2.
Step 8: Install the ES-00338 Potentiometer into the ES-00337 Dimmer Housing using the
hardware shown in Figure 2, orient the wires facing up. Install the ES-00339 Knob.
Step 9: Install the LC ECL-02 Red Eyeball Cockpit Light into the ES-00337 Dimmer
Housing with the mounting holes aligned. A couple small pieces of
double backed tape may be necessary to hold the LC ECL-02 to the
inside of the housing while riveting. This is now the Cockpit Lightand Dimmer Assembly.
Step 10: Crimp the L6028 (YEL/PRP) cockpit light wire
(part of the Main Wiring Harness) to the butt splice
on the red wire from the ES-00338 Potentiometer .
Step 11: Crimp the cockpit light ground wire (part of the Canopy Switch Ground Harness) to the butt splice on
the black wire from the LC ECL-02. Secure the F6035 Ring Terminal to the ground screw in the F-1232A, as
per Section 42MiS/U-10.
Step 12: Capture the butt splices and any extra wire inside the Dimmer Housing Assembly and rivet the
Cockpit Light and Dimmer Housing Assembly to the F-12124 as shown in Figure 1. The cockpit light ground
wire will exit the Dimmer Housing in the channel between the F-1231A-FR and the F-1231A-AR.
NOTE: For all installations, the nav/strobe switch must be in the NAV or NAV/STROBE position for the
cockpit lighting to be active.
FIGURE 2: WIRE
CONNECTIONS
FIGURE 1: INSTALLING THE
COCKPIT LIGHT
F-1231A-FR
F-1231A-FL
ROLL BAR ASSEMBLY
LP4-3
ALL F-12124 TO
F-1231A-FR RIVETS
GROUND SCREW
RIGHT LOWER RIVETS
AACQ-4-6
ALL F-12124 TO ES-00337
TO LC ECL-02 RIVETS
(LC ECL-02)
3X MACH CSK
FLUSH THIS SIDE
2X ES-00141
L7610 (NAV/COM)
L7269 (GARMIN)
L6348 (DYNON)
(RED)
F-12124
F6035
(BLACK)
L6028
(YEL/PRP)
WIRES PULLED THROUGH
SNAP BUSHING IN SECTION
42MiS/U
ES-00337
BLACK
(ES-00338)ES-00339
REDES-DV18-188-M
TO CANOPY SWITCH
COM TERMINAL
COCKPIT LIGHT GROUND WIRE
L7611 (NAV/COM)
L7270 (GARMIN)
L6349 (DYNON)
(BLACK)COCKPIT LIGHT AND
DIMMER ASSEMBLY
F-1232A
SUPPLIED WITH
ES-00338
MATCH-DRILL #30
F-12124
CHANNEL
F-1231A-AR
WH-00144
(ES-00338 & LC ECL-02)
